福特汽车采购系统介绍

Click to edit Master title style,Click to edit Master text styles,Second level,Third level,Fourth level,Fifth level,*,*,May 10, 2002,Premier Automotive Group,November 17,th, 2002,Speaker : Richard Chen,Vice President of Purchasing,Ford Lio Ho Motor Company,1.Opening Remarks,- Exercise,2.Fords Global Purchasing Overview,3.Supply Base Management,i. Supplier Improvement Metrics (SIM),ii. Product Development Advanced Product Quality Planning,iii. Production Systems Lean Manufacturing,iv. Material and Logistics Management,v. Cost Reduction,(ii,iv, v will not be covered due to time limit),4.Strategic Purchasing Tools and Processes,- Exercise,5.Annual Commodity Sourcing Strategy Review,Purchasing Management & Applications,2,公司的成長演變模式,跨國性公司,多元化產品公司,只重視,Core Business,的公司,-,Design,設計,-,Out sourcing: Development,& MFG activities,外包開發及 製造,-,Marketing & Sales,行銷,-,Service,售後服務,公司成長演變與採購組織職責的關聯,公司的成長演變模式,中小企業,單一產品公司,供應鏈完整的公司,-,Design,設計,-,Development,開發,-,Mfg.,製造 (,Made in Plant,內製),-,Marketing & Sales,行銷,-,Service,售後服務,3,單純採買行為,原物料,非生產物料,生產性物料,生產性零件,生產性模組,多功能採購,-,協力廠品質系統輔導,-,物流,- 國外市場採購,- 期貨市場採購,- 統合採購,- 衛星式聯合工廠聯盟,採購組織及職責,4,FAO Purchasing,COST TABLES,Exercise,Problem,:Purchasing has been asked to buy sweets for a Board Meeting. The dessert will be used in celebration of Fords superior market performance. We have been told that a key Board Member is constantly on the lookout for inefficient spending and our dessert purchase price could be challenged for its competitiveness. Therefore, our challenge is to buy the most dessert for the money and be prepared to prove it to the Board of Directors.,Instructions,The facing page details dessert/icing quotation summaries from five qualified sweets manufacturers. Our job is to find the best dessert buy for Ford. The best buy is defined by obtaining the most dessert for the least amount of money.,Calculate the “price per pound” for each dessert. Input answers in Section “A” of the facing page.,Plot the “price per pound” for ach of the five desserts on the graph marked “B”.,Questions,Which dessert Supplier has the lowest price per pound as indicated by the graph?,What is the “cost gap” dollar amount between the lowest and highest priced dessert?,If the high price dessert was adjusted to the most competitive “price per pound”, what percent savings would you request?,What cost drivers would you ask the high cost dessert Supplier take a look at to improve his/her pricing?,-,Extra Credit Challenge,What would be the lowest cost three (3) pound dessert your could create based on the best in class cost structure?,5,FAO Purchasing,COST TABLES,Exercise,6,7,如何培育採購人員來達成不同層次的採購職責,(,I),運用工業管理系,經濟系, 國際貿易系, 電機系, 機械系, 化工系, 會計系, 電子,商務系等所學之專長,(,II),良師益友培訓方式,(,III),教學是學習最有效的方法,(,IV),採購人員的,Leadership Behaviors,(,V),希望國內大學大專院校有開此課程, 目前福特六和都是自己,訓練採購人員,8,Buyers Leadership Behavior,誠信,實事求是,正確行事,力求多元化,工作完美無瑕,生意(業務)敏銳度,創新能力與專業水平,品質至上,勇氣,追求成效,顧客滿意度,關係,培養人才與團隊精神,與顧客溝通,服務社區,9,Global Purchasing Overview,全球,採購,概,況,10,#4,ontheFortune500,在,財星,500,大,排名,第,第4,#4,ontheGlobal500,全球500,大企,業,業,排名,第,第4,12%,ofGlobalMarketShare,2,nd,LargestManufacturerinWorld,擁有,全,全球,12%,市場,佔,佔有,率,率,全球,排,排名,第,第二,的,的汽,車,車製,造,造商,Over375,000employeesworldwide,全球,共,共有,超,超過,37.5,萬員,工,工,110,assemblyandmanufacturingsitesworldwidein40countries,在,40,個國,家,家擁,有,有,110,個裝,配,配和,製,製造,據,據點,FORDFACTS,福特,概,概況,Ford,（,福特,）,Mazda,（,馬自,達,達,）,Volvo,（,富豪,）,Mercury,（,水星,）,Lincoln,（,林肯,）,LandRover,（,路華,）,Jaguar,（,積架,）,AstonMartin,（,阿斯,頓,頓,馬丁,）,Total,（,總計,）,2001,Production,2001,年生,產,產情,況,況,(,numberofunits),(,輛,),5,627,000,841,000,411,000,364,000,186,000,164,000,128,000,1,000,7,722,000,ANDHOWDOESPURCHASINGFITIN?,採購,扮,扮演,的,的角,色,色,?,7.7,MillionVehicles,770,萬輛,汽,汽車,US$90BillionAnnualTurnover,900,億美,元,元的,年,年營,業,業額,2000,ProductionSupplierParentCompanies,2000,家製,造,造供,應,應商,母,母公,司,司,5000,ProductionSupplierManufacturingSites,5000,個供,應,應商,生,生產,基,基地,9000,Non-ProductionSuppliers,9000,家非,生,生產,供,供又,商,商,130,000,ProductionParts,13,萬種,生,生產,零,零配,件,件,110,FordAssemblyandManufacturingSites,110,個福,特,特裝,配,配和,生,生產,基,基地,Suppliersin44Countries,供應,商,商分,佈,佈於,44,個國,家,家,Buying,（,採購,）,Production,Material,生產性物料,Non-Production,Material,非生產性物料,Supplier Technical,Assistance,供應商技術支援,North America,Purchasing,北美採購,CBG,(1),Leader,業務小組負責人,South America,Purchasing,南美,採購,CBG,(1),Leader,業務小組負責人,Europe,Purchasing,歐,洲,採購,CBG,(1),Leader,業務小組負責人,Asia,Purchasing,亞洲採購,CBG,(1),Leader,業務小組負責人,Tony Brown, Global Purchasing Vice President,全球採購副總裁,FORDGLOBALPURCHASINGORGANIZATION,全球,福,福特,採購,組,組織,CSO,(2),*,Establish China Sourcing Office,建立中國採購小組,*,Identify and develop,highly capable suppliers,尋找和開發能力強的供應商,Global Sourcing Development Team,（,全球,資,源,發,展,組),）,CBGLeader=CustomerBusinessGroupLeader（,業務,小组,負責,人),CSO=ChinaSourcingOffice（,中國,採,採購,小,小組,）,14,SUPPLIERRELATIONSHIPVALUES,與,供應,商,商關,係,係的,重,重要,性,性,ActLikeaPartnertobeaPartner,像真,正,正的,合,合伙,人,人一,樣,樣合,作,作,TrustandbeTrustworthy,信任,對,對方,並,並且,自,自身,值,值得,信,信任,CommunicatewithConsistency,持續,性,性的,溝,溝通,BeFact-Based,以事,實,實為,基,基礎,ThinkValuenotJustPrice,著重,價,價值,而,而不,僅,僅僅,是,是價,格,格,.,tobetheCustomerofChoice,成為,理,理想,的,的客,戶,戶,15,QUALITYISOURTOPPRIORITY,品質,是,是我,們,們的,首,首要,目,目標,16,WEWORKTOBUILDQUALITYVEHICLESFOROURCUSTOMERSAROUNDTHEWORLD,我們,要,要為,全,全球,客,客戶,製,製造,高,高品,質,質的,汽,汽車,andoursuppliersarethefoundationofsuccessinvehiclequality,供應,商,商是,我,我們,確,確保,汽,汽車,品,品質,的,的基,礎,礎,17,WHATDOWEEXPECTFROMSUPPLIERS?,我們,對,對供,應,應商,的,的期,待,待,?,EverysuppliertoFordisexpectedtoachieveandmaintainourQ1suppliercertification,每個,供,供應,商,商都,需,需要,獲,獲得,並,並保,持,持我,們,們的,Q1,供,應,應,商,商,品,品,質,質,認,認,證,證,Thefirststepisachieving:,獲,得,得,的,的,第,第,一,一,步,步,QS-9000,ISO14001,Q1,18,OURSUPPLYQUALITYENGINEERSWORKWITHYOUONSITE,我,們,們,的,的,品,品,質,質,技,技,術,術,工,工,程,程,師,師,參,參,與,與,並,並,協,協,助,助,現,現,場,場,實,實,務,務,ThenextstepistoassignaSupplierTechnicalAssistantEngineer(STA)whowillvisityourmanufacturingsiteto:,下,一,一,步,步,是,是,指,指,派,派,一,一,位,位,技,技,術,術,輔,輔,導,導,工,工,程,程,師,師,(,STA),訪,察,察,供,供,應,應,商,商,製,製,造,造,現,現,場,場,:,Checkforhighqualitystandardsonparts,檢,查,查,零,零,件,件,部,部,品,品,是,是,否,否,符,符,合,合,高,高,品,品,質,質,標,標,準,準,Ensurerobustmanufacturingcapability,確,保,保,強,強,勁,勁,的,的,生,生,產,產,能,能,力,力,Identifyandmakeplansforareasofimprovement,對,所,所,需,需,改,改,進,進,的,的,領,領,域,域,做,做,改,改,善,善,計,計,劃,劃,SharelessonslearnedfromNorthAmerica,與,供,供,應,應,商,商,共,共,享,享,北,北,美,美,市,市,場,場,經,經,驗,驗,19,STAENGINEERSLOOKFORMANUFACTURINGBASICSANDAPPROACHTOPLANNING,技,術,術,輔,輔,導,導,工,工,程,程,師,師,致,致,力,力,於,於,將,將,製,製,造,造,的,的,基,基,本,本,要,要,點,點,和,和,步,步,驟,驟,與,與,供,供,應,應,商,商,的,的,規,規,劃,劃,相,相,結,結,合,合,QualityProcedures,品,質,質,程,程,序,序,QS-9000,QualityOperatingSystems(QOS),品,質,質,操,操,作,作,體,體,系,系,FailureModeandEffectsAnalysis(FMEAs),失,效,效,模,模,式,式,和,和,效,效,果,果,分,分,析,析,ControlPlans,控,制,制,計,計,劃,劃,Pre-ProductionPartApprovalProcesses(PPAPs),生,產,產,前,前,零,零,件,件,部,部,批,批,准,准,程,程,序,序,（,PPAPs,）,）,RunatRateReview,“,批量生,產,產,”,審核,EmployeeReadiness/TrainingReview,員工準,備,備情況,/,培訓審,核,核,Managethe ChangeinManufacturing andDesign,管理生,產,產與設,計,計所涉,及,及的變,化,化,20,ANDALSOREQUIRE ON SITEDEMONSTRA-TIONSOFMANUFACTURING CAPABILITY,並且要,求,求在製,造,造現場,的,的實作,驗,驗證能,力,力,Sub-supplierQualityManagement,二階供,應,應商品,質,質管理,Control of Incoming Quality,進料品,質,質的控,管,管,Control Plans/Operator Instructions,管控計,劃,劃,/,操作說,明,明,Process Variability Monitoring,製程變,異,異監督,Gage Calibration andUse,量具,校正及,運,運用,Part I.D., NonconformingPartsHandling,Packaging, Shipping,零件標,示,示,不良品,處,處理,包裝和,運,運輸,Testing,EngineeringSpecifications,測試,工程規,格,格,Preventive Maintenance (PM)/Housekeeping*,預防性,維,維護,/,內務管,理,理,Manufacturing Flowand LeanManufacturingMetrics*,生產流,程,程精益,生,生產衡,量,量,Problem-Solving, CorrectiveActions,問題的,解,解決,更正措,施,施,21,ACHIEVINGQ1REQUIRESPROVEN RESULTS,Third-PartyCertification of QS-9000and ISO14001,Acceptable OnsiteAssessment by STAEngineer,6,monthsofproductionshippinghistory withnoproblems,EndorsementsfromYour FordCustomers (Ford manufacturingplants,MaterialsPlanningand Logistics,SupplierQuality,etc.),YouhaveachievedQ1!,22,WHAT DO WE EXPECTFROM SUPPLIERSONANONGOING BASIS?,Keep yourQ1bymaintainingexcellencein:,Quality,Efficiency/Waste Elimination,Delivery,Have resourcesavailabletosupportlaunchesofFord vehicles,Advancedproduct qualityplanning,Launchreadiness reviewsonsite,Collaborateclosely withFordtoresolve anyissuesthatmightariseonpart qualityordesign,Weworkedtogetherwithsuppliers,23,Buying,（,採購,）,Production,Material,生產性材料,Non-Production,Material,非生產性材料,Supplier Technical,Assistance,供應商技術支援,North America,Purchasing,北美,採購,CBG,(1),Leader,業務,小组,負,责人,South America,Purchasing,南美,採購,CBG,(1),Leader,業務,小组,負,责人,Europe,Purchasing,欧洲,採購,CBG,(1),Leader,業務,小组,負,责人,Asia,Purchasing,亚洲,採購,CBG,(1),Leader,業務,小组,負,责人,Tony Brown, Global Purchasing Vice President,全球,採購副總裁,FORD GLOBALPURCHASINGORGANIZATION,全球福,特,特,採購組,織,織,CSO,(2),*,Establish China Sourcing Office,建立中,國採購,小组,*,Identify and develop,highly capable suppliers,發現和發展高能力的供應商,Global Sourcing Development Team,（,全球資源發展組,）,CBGLeader =CustomerBusinessGroupLeader（,業務小,組,組負責,人,人,),CSO=ChinaSourcingOffice,（,（,中國採,購,購小組,）,24,WHAT IS FORDLOOKINGFORINCHINA?,WorldClassQuality,Cost Advantage,Delivered to Assembly,AllParts,StrongExport Track Record,Commitment to CorporateResponsibility,25,BENEFITSFORSUPPLIERS IN CHINA,對,中,國,供,應,商的益,處,Increasedexports,增加出,口,口額,Improvedscale,增加生,產,產規模,Exposuretomultiplepotentialcustomers in Ford,sglobalautomotivebusinesses,通過福,特,特全球,汽,汽車業,務,務而增,加,加與潛,在,在客戶,的,的接觸,和,和瞭解,Improvedsupplychaincapabilities,提高供,應,應鍊生,產,產能力,Accesstolonger termtechnologicaladvancements,獲得長,期,期的技,術,術改進,Potentialtoparticipateinfuture localizationopportunities withFordChina,今後與,福,福特在,中,中國進,行,行更多,地,地方性,合,合作的,機,機會,Improvedglobalcompetitiveness,提高全,球,球競爭,能,能力,26,AIMTOREPLICATE SUCCESSINEASTERNEUROPE,目,標,:,複製在,東,東歐的,成,成功經,驗,驗,1997,1998,1999,2000,2001,$1.4,BILLION,（,14,億,美元）,$0,Quality betterthan previous sources!,比原有,供,供,應,商具有,更,更好,質,量!,Country Offices,在國內的業務機構,Dedicated Sourcing Development Team,專注的採購發展團隊,Company Wide Support in Ford,福特公司全體的支持,Highly Capable Suppliers,能力強的供應商,Keys to Success,（,成功的,關鍵,）,：,In China,（,在中,國,）？,27,EXAMPLESOFPOTENTIALCOMMODITIES,SOURCED TO SUPPLIERSINCHINA,列舉可,能,能向,中,國,供,應,商,採購的,零,零組件,SHORTTERM,（,短期）,:,Wheels,（,輪胎,）,Driveshafts,（,轉動軸,）,Stabilizer Bars,（,平衡桿,）,Coil Springs,（,螺旋彈,簧,簧,）,Side Glass,（,側窗玻,璃,璃,）,Speakers,（,揚聲器,）,DieCastings,（,壓鑄,）,Batteries,（,電池,）,Leaf Springs,（,鋼板彈,簧,簧,）,LONGERTERM,（,中長期,）,:,Radios/AudioSystem,（,收音機,/,音響系,統,統,）,Wiring,Harness,（,線束,）,Rear Axles,（,後軸,）,Half shafts,（,半,軸,）,Lighting,（,車燈,）,CylinderHeads/Blocks,（,氣缸頭,/,體,）,Exhaust Manifolds,（,排氣岐,管,管,）,Camshafts/Crankshafts,（,凸轉軸,/,曲軸,）,Intake Manifolds,（,進氣岐管,）,Balance Shafts,（,平衡軸,）,28,OVERVIEW -FORDOPERATIONS INGREATER CHINA,概述,福特在大中,華,華地區的業,務,務,CAF,Nanchang,JMC,南昌江鈴汽,車,車,FordMotorChina Ltd. (HoldingCompany),福特汽車中,國,國有限公司,（,控股公司,）,FMCCRepresentativesOffice (Beijing),福特信貸代,表,表處,（,北京,）,Taiwan,FordLio Ho,(70/30 JV),台湾福特六,和,和汽,車,（70/30合,資,企,業,）,Chongqing,Changan-Ford,重慶長安,-,福特,Beijing,北京,Tianjin,FMITT,福特汽車天,津,津國際貿易,有,有限公司,29,FORDOPERATIONSIN GREATER CHINA,福特在大中,華,華地區的業,務,務,History ofFordin Greater China,福特在大中,華,華地區的歷,史,史,1913,First Model-Ts Sold In China,第一,輛,福特汽,車,Model-T,在中,國銷,售,1972,Established Ford LioHo Taiwan (70/30 JV),福特六和在台,灣,成立（70/30合,資,企,業,）,1980,Launched Visiting Engineering Program,啟動工程技術人員訪問項目,1995,Established Ford Motor (China) Ltd.,福特汽,車,中,國,有限公司成立,1995,Established Five Components JVs,建立了五家汽,車,零部件合,資,企,業,1995,Acquired Equity in Jiangling Motors (JMC),收,購,江,鈴,汽,車,（,JMC）,的股,權,1996,Established Ford Credit Representatives Office,福特信贷代表,處,成立,2000,Launched Ford Motor Conservation & Environmental Grants,啟動節約與環境保護項目,2000,Spun-off Component JVs (Visteon),零部件合,資企業隨著傅世通獨立,2001,Established Changan Ford Automobile Co. (50/50 JV),長安福特汽車公司成立,（50/50合,資,）,2001,Established Ford Motor International Trading (Tianjin),福特汽,車,天津,國際,贸易有限公司,成立,30,FORDOPERATIONSIN GREATER CHINA,福特在大中,華,華地區的業,務,務,FordMotor(China) Ltd. Holding Company(100%),福特汽,車,（中,國,）有限公司,（,（100%,）,）,50/50,Changan-Ford Joint Venture (Passenger Car),50/50,股,權,比例的,長,安 福,特,特汽,車,股份有限公,司,司（,轎車,）,30%,FordEquity Investment inJMC(Transit),控制江,鈴,汽,車,30%的股,份,份（全,順,）,Marketing,Sales andService Operations,市,場營銷,、,銷,售以及服,務業務,FordMotorInternationalTrading Tianjin(FMITT) 100%,福特汽車天,津,津國際貿易,有,有限公司,（,FMITT,）,）100%,控股,OtherKeyFunctions:GA,PA, HR, Legal,Finance Business Development &Product Planning,其它重要職,能,能,：,政府事務,，,公共事務,，,人力資源,，,法律,，,融資業務發,展,展以及產品,計,計劃,31,FordLio-Ho Taiwan,台灣福特六,和,和汽車,Established in1972,於,1972,年成立,70/30,JV Ownership Structure,70/30,的合資股權,結,結構,CKD Operations,CKD,業務,Located intheCityof Chung-Li,位於中壢,MajorProducts:Tierra, Mondeo, Escape,Ixion, Pronto,and Econovan,主要產品,：,Tierra, Mondeo,Escape, Ixion,Pronto, and Econovan,FORDOPERATIONSIN GREATER CHINA,福特在大中,華,華地區的業,務,務,32,FiveFormer Components JVs (VisteonSpin-off),五家先前有,合,合資的汽車,零,零部件企業,（,隨偉世通獨,立,立,）,Shanghai FuHuaAutomotiveGlass (51/49 JV With YaoHua),上海福華汽,車,車玻璃,（,與耀華玻璃,51/49,的合資企業,）,Shanghai YanFeng Automotive Trim (50/50JV With SAIC),上海延鋒汽,車,車內飾件,（,與上汽集團,50/50,的合資企業,）,Shanghai FudianAutomotive Electronics (70/30JV With Shanghai Automation Instrument),上海福電汽,車,車電子,（,與上海自動,儀,儀表,70/30,的合資企業,）,United AluminumRadiatorCompany (50/50JV With FAW),聯合鋁散熱,器,器,（,與一汽集團,50/50,的合資企業,）,JiangXi FuchangClimate SystemLtd.(81/19 JVWithJMC),江西福昌汽,車,車空調系統,（,與江鈴汽車,81/19,的合資企業,）,FORDOPERATIONSIN GREATER CHINA,福特在大中,華,華地區的業,務,務,33,FordFinancialBeijing Representative Office,福特財務北,京,京代表處,Established December1996,於,1996年12月成立,Business Development,業務拓展,FordFinancialChina,福特中國財,務,務有限公司,Working W/Govt toEstablisha Auto Financing Operation,與政府共,同,同建立一,家,家汽車融,資,資企業,Retail and WholesaleFinancing for FordFamily Brands,為福特的,各,各種品牌,進,進行零售,及,及批發業,務,務方面的,融,融資,CommenceEarly 2003to Support C195Launch,將於,2003,年,年初正式,營運,，以支持,C195,的投,產,FORDOPERATIONSIN GREATER CHINA,福特在大,中,中華地區,的,的業務,34,Jiangling MotorCo.(JMC),江鈴汽車,有,有限公司,（,JMC）,A PublicListedCompanyUnder JMC GroupCo.(SOE),江鈴汽車,集,集團,（,國有企業,）,下的一家,上,上市公司,FordHas30%EquityPosition,福特擁有,30%,的股權,Locatedin Nanchang,JiangxiProvince,位於江西,省,省南昌市,Major Products:Isuzu-basedCommercial &Ford Transit,主要產品,：,五十鈴系,列,列的商用,車,車以及福,特,特全順,Profitable Operations DuringPast Two Years,過去兩年,均,均有贏利,表,表現,FORDOPERATIONSINGREATERCHINA,福,特,特,在,在,大,大,中,中,華,華,地,地,區,區,的,的,業,業,務,務,35,ChanganFordAutomobileCo.Ltd.(CAF),長,安,安,福,福,特,特,汽,汽,車,車,股,股,份,份,有,有,限,限,公,公,司,司,（,CAF,）,）,50/50JVWithChanganAutomobile,與,長,長,安,安,汽,汽,車,車,組,組,建,建,的,的,50/50,合,資,資,企,企,業,業,JVApproved(April,2001),合,資,資,企,企,業,業,獲,獲,得,得,批,批,准,准,（2001,年,年4,月,月,）,）,NewGreenfieldFacilityUnderConstructioninCQ,在,重,重,慶,慶,的,的,新,新,的,的,廠,廠,房,房,及,及,設,設,備,備,正,正,在,在,建,建,設,設,中,中,Job#1TargetedforEarly2003,目,標,標,於,於,2003,年,初,初,投,投,產,產,FirstProductIsaSmallPassengerCar,首,要,要,產,產,品,品,為,為,小,小,型,型,轎,轎,車,車,NewRetailNetworkofFordFranchisedDealersSelected,由,福,福,特,特,特,特,約,約,經,經,銷,銷,商,商,構,構,成,成,的,的,全,全,新,新,的,的,零,零,售,售,網,網,路,路,已,已,經,經,選,選,定,定,FORDOPERATIONSINGREATERCHINA,福,特,特,在,在,大,大,中,中,華,華,地,地,區,區,的,的,業,業,務,務,36,ChanganFord(CAF)RetailDistributionNetwork,長,安,安,福,福,特,特,（,CAF,）,）,零,售,售,分,分,銷,銷,體,體,系,系,25,Dealers(3in1),Sales,Service,Parts,25,個,經,經,銷,銷,商,商,（,三,合,合,一,一,）-,銷,售,售,，,服,務,務,，,零,部,部,件,件,供,供,應,應,ConsistentBrandRetailStandard,統,一,一,的,的,品,品,牌,牌,與,與,零,零,售,售,標,標,準,準,SellBUandLocallyProducedFord,同,時,時,銷,銷,售,售,進,進,口,口,以,以,及,及,當,當,地,地,生,生,產,產,的,的,福,福,特,特,汽,汽,車,車,Shanghai,上,海,海,Guangzhou,廣,州,州,Chongqing,重,慶,慶,Beijing,北,京,京,FORDOPERATIONSINGREATERCHINA,福,特,特,在,在,大,大,中,中,華,華,地,地,區,區,的,的,業,業,務,務,37,ThePurposeofSIM,Siteimprovementmetrics(SIM)isaweb-basedapplicationthattracksandreportsdataonsiteperformancebasedonastandardsetofmetricsdefinedbyFORD.,TheSIMapplicationdrawstogetherdatathatiscapturedinoperationalsystemsthroughoutFordandconsolidatesitintoonelocationforeasyaccessanduse.,38,The Role of SIMin Site Management,SIM provides data that can beusedto:,Improve communication throughstandardized data providetheperformance metricsusedin Q1scoring,Improve communications throughstandardizeddataand dailyQR detailupdates,Identify opportunities for continuous improvement,Measure site performanceto supportoperational processes,39,AnalyzingSIM Data,The Site Summary screen is theprimary screenusedforsitemanagementandcontains the following sections:,Contacts,Q1 Information,On-Going Performance,!,PPM,!,Delivery,!,FieldActions,!,StopShipments,!,PSW (not used in Q1scoring),!,SiteResponsible Issues (Not used in Q1scoring),40,Advantageof SIM,Referenceof globalpurchasing,Provide realistic information,Reduce manual mistake andoperationwaste,Provide continuouslyimprovement metrics,41,Suppliers,Warehouse,(MP&L),CMMS3,IQC,PPM Report,Supplier,Improvement,Metrics (SIM),M6 Form,(DF & DA),Quantity,GSDB,STA,Current PPM Process,42,43,QC Manager,PlantManager,Delivery Champion,Responsible STAEngineer,44,Q1 Information,Defect Parts,PPM Record,45,Delivery,Performance,Field Action &,Stop Shipments,46,精實製造,LeanManufacturing,它是什麼?,是一種在價,值,值流(,valuestream),中藉由,排除浪費,以提昇流動,性,性，使其能,獲,獲致更短的,前,前置時間，,從,從而提供高,品,品質、低成,本,本的製造,哲學,由產品開發,、,、程序工程,、,、營運管理,及,及企業總管,理,理作業等所,組,組成的一整,合,合性系統，,其,其能為顧客,提,提供價值及,帶,帶給人們尊,嚴,嚴,47,福特原始的,生,生產哲學,Ford,s OriginalManufacturingPhilosophy(1926),標準化及持,續,續改善,StandardizationandContinuousImprovement,減少浪費,EliminateWaste,採用連續生,產,產模式,Use ContinuousFlowManufacturing,物料在來源,處,處即採品質,管,管理,Practice Quality atthe Source,摘錄自亨利,福,福特的著作,今日與明日,From,TodayandTomorrow,by Henry Ford,48,Kaizen (,改善,),只是其中的,一,一部份,精實生產是,一,一種系統.,問題解決,防呆措施,快速換模換線,全面生產性維護,5,S /,目視化工廠,看板,(,Kanban,),Kaizen,精實生產概論,標準作業,49,為什麼需要,精,精實,?,競爭上,壓力,品質,成本,速度,驅動作,業流程,顧客滿意,零不良,訂購到交貨,可負擔的,事業架構,降低成本,後勤補,給,精實生產,預防不良,小批量生產,降低生產,前置時間,提昇生產力,50,製造競爭優,勢,勢,以精實生產,提,提升生產力,及,及品質,降,降低成本,形,形成企業,的,的競爭優勢,51,從何處著手,.,整體價值鍊,52,整體價值鍊,裝配廠,運送,售後服務,及保證,目前我們身,處,處何處 ?,原材料,第,1,階,協力廠,第,X,階,53,鑄造工廠,第1階協力,廠,廠商,內裝產品協,力,力廠商,內裝產品協,力,力廠商,第2階,第2階,第2階,第2階,第2階,第3階,第3階,第3階,第3階,價值鍊,裝配廠,54,衡量指標,總成本,(,TotalCost),首次合格率,(,FTT),製造週期時,間,間,(,MCT),進料倉庫到,出,出貨倉庫時,間,間,(,DTD),總和設備效,率,率,(,OEE),55,總體成本,勞務及間接,費,費用僅只是,總,總成本中的,一,一部份,原物料/外,購,購部品,勞務及間接,費,費用,索賠,運輸,其他,25%,60%,直接員工,(12)%,5%,5%,5%,56,衡量指標,總成本,(,TotalCost),首次合格率,(,FTT),製造週期時,間,間,(,MCT),進料倉庫到,出,出貨倉庫時,間,間,(,DTD),總和設備效,率,率,(,OEE),57,A,B,C,D,100/100 =1,85/87= .98,87/90= .97,90/100 = .9,100,90,87,計算最終産,合,合格率(傳,統,統),合格率是多,少,少?,1 .9 .97 .98,= 85%,廢品,廢品 10,廢品 3,廢品2,産出 =,未,未作廢的單,位,位數,開始: 100 個單,位,位,結束:85,個,個“良好”,的,的單位,58,A,B,C,D,100,90,87,10,6,9,5,一次通過合,格,格率及隱藏,工,工廠,100-10(返工+,廢,廢品)/100= .90 一次,通,通過合格率,87-7(返工+廢,品,品)/87= .91一次通過,合,合格率,90-12(返工+廢,品,品)/90= .86一次通過,合,合格率,100-16(返工+,廢,廢品)/100= .84一次通,過,過合格率,廢品,一次通過合,格,格率= 未,作,作廢或,返工的單位(59%),返,工,隱藏,工廠,廢品 10,廢品 3,廢品2,開始: 100 個單,位,位,結束:85,個,個“良好”,的,的單位,59,衡量指標,總成本,(,TotalCost),首次合格率,(,FTT),製造週期時,間,間,(,MCT),進料倉庫到,出,出貨倉庫時,間,間,(,DTD),總和設備效,率,率,(,OEE),60,進料倉庫到,出,出貨倉庫時,間,間,(,DTD),製造週期時,間,間,(,MCT),出貨,進料,進料倉庫,成品倉庫,生產製造過,程,程,衡量指標,61,衡量指標,總成本,(,TotalCost),首次合格率,(,FTT),製造週期時,間,間,(,MCT),進料倉庫到,出,出貨倉庫時,間,間,(,DTD),總和設備效,率,率,(,OEE),62,重新檢視競,爭,爭優勢,以精實生產,提,提升生產力,及,及品質,降,降低成本,形,形成企業,的,的競爭優勢,Dock- to- Dock,成本管理,時效管理,品質管理,63,重新檢視競,爭,爭優勢,DTD,的管理與財,務,務管理,庫存周轉率= 庫存,量,量 / 營,業,業額,64,總和設備效,率,率,(,OEE),OEE,是用來衡量,一,一項設備的,稼,稼動率、性,能,能效率以及,良,良品率。,對一瓶頸作,業,業而言，,OEE,是衡量產能,利,利用率的指,標,標。,OEE=,稼動率,x,性能效率,x,良品率,(作業),65,全負荷理想,產,產能,計劃稼動理,想,想產能,換線及故障,損,損失後產能,作業等待及,未,未遵守標準,等,等損失後產,能,能,品質不良損,失,失後產能,未計劃生產,的,的產能損失,實際產能,OEE,損失的產能,總和設備效,率,率,(,OEE),66,OEE (Constraint),48,66,81,86,83,75,0,50,100,1,2,3,4,5,6,Month,OEE %,良品率,生產總數,良品數,不良品數,性能效率,作業紀律,小的作業等,待,待或中止,稼動率,換模換線時,間,間,非預期故障,時,時間,總和設備效,率,率,67,精實生產,專注在,:,排除價值流,中,中的浪費,連續流動生,產,產, 由顧,客,客拉提式生,產,產,儲存,進料倉庫,沖壓,點焊,裝配,生產控制,協力廠商,顧客,修補,交運清單,預測量,訂單,交貨,物料,排程 &,生,生產跟催,出貨倉庫,預測量,訂單,排程 &,生,生產跟催,排程 &,生,生產跟催,儲存,儲存,儲存,訂單,現金,68,標準,作,作業,StandardizedWork,防止,錯,錯誤,ErrorProofing,目視,管,管理,Visualcontrols,預防,性,性維,護,護,Preventivemaintenance,工作,地,地點,的,的組,織,織,Workplaceorganization,貨櫃,化,化,Containerization,拉式,生,生產,Pullsystems,小批,量,量生,產,產,Smalllotproduction,低庫,存,存,Lowinventory,團隊,精,精神,Workteams,現場,佈,佈置,流,流程,Layout/flow,快速,換,換模,換,換線,Quicktoolchangeover,產出,時,時間,Throughputtime,檢查,重,重